Transfer system including a cam actuated segmented flexible transfer assist blade

Abstract: A transfer system including a contact member (81,82) for applying pressure against a copy substrate to create uniform contact between the copy substrate and a developed image on an imaging member (10). The transfer system includes a flexible transfer assist blade (82) and a rotatable cam (84) shaft having a lobe for deflecting the transfer assist blade into contact with the copy substrate. Alternatively, the transfer assist blade may include multiple segments and the rotatable cam shaft may include a plurality of lobes, each having a lengthwise dimension corresponding to predetermined segments of the blade for providing contact across a dimension corresponding to that of the copy substrate. The system further includes a stepper motor for rotating the cam to predetermined angular positions to create an abutting relationship between the lobe and the transfer assist blade for deflecting selected segments of the blade toward the copy substrate. The transfer assist blade presses the copy sheet into contact with at least the developed image on the photoconductive surface to substantially eliminate any spaces or gaps between the copy sheet and the developed image during transfer of the developed image from the photoconductive surface to the copy sheet.

Description: The present invention relates generally to a system for assisting transfer of a developed image to a copy substrate in an electrostatographic printing apparatus, and more particularly concerns an apparatus for enhancing physical contact between the copy substrate and the developed image situated on a photoreceptive member. Generally, the process of electrostatographic copying is initiated by exposing a light image of an original document onto a substantially uniformly charged photoreceptive member Exposing the light image onto the charged photoreceptive member discharges a photoconductive surface thereon in areas corresponding to non-image areas in the original document while maintaining the charge in image areas, thereby creating an electrostatic latent image of the original document on the photoreceptive member. Thereafter, developing material comprising charged toner particles is deposited onto the photoreceptive member such that the toner particles are attracted to the charged image areas on the photoconductive surface to develop the electrostatic latent image into a visible image. This developed image is then transferred from the photoreceptive member, either directly or after an intermediate transfer step, to an image support substrate such as a copy sheet, creating an image thereon corresponding to the original document. The transferred image is typically affixed to the image support substrate to form a permanent image thereon through a process called "fusing". In a final step, the photoconductive surface of the photoreceptive member is cleaned to remove any residual developing material thereon in preparation for successive imaging cycles. The electrostatographic copying process described above is well known and is commonly used for light lens copying of an original document. Analogous processes also exist in other electrostatographic printing applications such as, for example, digital printing where the latent image is produced by a modulated laser beam, or ionographic printing and reproduction, where charge is deposited on a charge retentive surface in response to electronically generated or stored images. The process of transferring charged toner particles from an image bearing member such as the photoreceptive member to an image support substrate such as the copy sheet is realized at a transfer station. The transfer process is enabled by overcoming adhesive forces nolding the toner particles to the image bearing member in a conventional electrostatographic machine, transfer is achieved by transporting the image support substrate into the area of the transfer station where electrostatic force fields sufficient to overcome the forces holding the toner particles to the photoconductive surface are applied to attract and transfer the toner particles over onto the image support substrate. In general, transfer of developed toner images in electrostatographic applications has been accomplished via electrostatic induction using a corona generating device, wherein the image support substrate is placed in direct contact with the developed toner image on the photoconductive surface while the reverse side of the image support substrate is exposed to a corona discharge. This corona discharge generates ions having a polarity opposite that of the toner particles, thereby electrostatically attracting and transferring the toner particles from the photoreceptive member to the image support substrate. An exemplary corotron ion emission transfer system is disclosed in US-A-2,836,725. Unfortunately, the interface between the photoreceptive surface and the image support substrate is not always optimal. Problems may occur in the transfer process when spaces or gaps exist between the developed image and the image support substrate. There is a tendency for toner not to transfer across these gaps, causing a copy quality defect referred to as "transfer deletion". In particular, non-flat or uneven image support substrates, such as copy sheets that have been mishandled, left exposed to the environment or previously passed through a fixing operation (e.g, heat and/or pressure fusing) tend to promulgate imperfect contact with the photoreceptive surface of the photoconductor. As described, the process of transferring development materials in an electrostatographic system involves the physical detachment and transfer-over of charged toner particles from an image bearing photoreceptive surface into attachment with an image support substrate via electrostatic force fields. One critical aspect of the transfer process is focused on the application and maintenance of high intensity electrostatic fields in the transfer region for overcoming the adhesive forces acting on the toner particles as they rest on the photoreceptive member. In addition, other forces, such as mechanical pressure or vibratory energy, have been used to support and enhance the transfer process. Careful control of these electrostatic fields and other forces is required to induce the physical detachment and transfer-over of the charged toner particles without scattering or smearing of the developer material. The problem of transfer deletion has been addressed through various approaches. For example, an acoustic agitation system incorporating a resonator suitable for generating vibratory energy arranged in line with the back side of the photoconductor to apply uniform vibratory energy thereto has been disclosed in commonly assigned US-A-5,081,500 as a method for enhancing toner release from the photoreceptive surface. In accordance with the concept of that patent, toner can be released from the image bearing surface of the photoconductor despite the fact that electrostatic charges in the transfer zone may be insufficient to attract toner over to the image support substrate Alternatively, mechanical devices that force the image support substrate into intimate and substantially uniform contact with the image bearing surface have been incorporated into transfer systems. Using this approach, various contact blade arrangements have been proposed for sweeping over the back side of the image support substrate at the entrance to the transfer region. The present invention is directed toward such a mechanical device wherein a flexible transfer assist blade is deflected against a copy sheet. The following disclosures may be relevant to various aspects of the present invention. US-A-4,947,214 to Baxendell et al. discloses a system for transferring a developed image from a photoconductive surface to a copy sheet, including a corona generating device and a transfer assist blade. The blade is shifted via a solenoid-activated lever arm from a non-operative position spaced from the copy sheet, to an operative position. in contact with the copy sheet for pressing the copy sheet into contact with the developed image on the photoconductive surface to substantially eliminate any spaces therebetween during the transfer process. Although a practical implementation of that patent has been utilized with relative success in the Xerox Corporation model 5090 Duplicator, Baxendell, et al. provide an embodiment wherein a load is normally applied to the transfer assist blade for deflecting the blade in its non-operative position, the load being removed (by means of a solenoid) to allow the blade to move to its operative position. It has been found that this sustained load on the blade while in its non-operative position reduces the life expectancy of the blade and causes stress failures, resulting in more frequent servicing of the machine. EP-A-0,584,928 discloses a transfer blade for ironing a sheet against a photoreceptor belt during transfer, thereby smoothing out deformities which cause deletions. The transfer blade of that patent application includes a flexible tip to absorb the impact of the blade as it contacts the paper and a spring load to limit and control the force applied to the sheet. Sensors are also utilized to monitor and adjust the timing of the transfer blade. EP-A-0,388,342 discloses an electrophotographic machine in which flexible support members are movably mounted to mechanically press print paper against the photoreceptor surface within the transfer zone. EP-A-0,584,928 discloses a mechanism for enhancing contact between a copy sheet and a developed image, the mechanism including a contact member which is indirectly actuated by a cam/cam follower arrangement through a series of linkages. In accordance with one aspect of the present invention, there is provided an apparatus for providing substantially uniform contact between a copy substrate and a developed image located on an imaging member, comprising contact means, adapted to move from a non-operative position spaced from the imaging member to an operative position in contact with the copy substrate on the imaging member, for applying pressure against the copy substrate in a direction toward the imaging member, and means, including a rotatable cam member comprising a cam lobe, for applying a load to the contact means to deflect the contact means into the operative position. In accordance with another aspect of the present invention, there is provided an electrostatographic printing machine including a transfer station for transferring a developed image from a moving imaging member to a moving copy substrate, including an apparatus for providing substantially uniform intimate contact between the copy substrate and the developed image located on the imaging member, as described above. These and other aspects of the present invention will become apparent from the following description in conjunction with the accompanying drawings, in which: FIG. 1 is an enlarged schematic elevational view showing the transfer assist apparatus of the present invention; FIG. 2 is a plan view showing the segmented flexible transfer assist blade and the actuating cam of the present invention; FIG. 3 is a perspective view of an actuating cam which may incorporated into the transfer assist apparatus of the present invention; FIG. 4 is a perspective view of an alternative embodiment of the actuating cam of FIG. 3. The transfer assist apparatus of the present invention may be included in an electrophotographic reproducing apparatus, which may take the form of any of several well known devices or systems such that various specific electrostatographic processing subsystems or processes may be used without affecting the operation of the present invention. With reference to FIG. 1, the transfer assist apparatus is depicted in side view to reveal the various components included therein. As shown in this figure, feed rollers 53 and 55 are rotated in opposite directions for transporting a sheet of copy substrate (not shown) toward transfer assist blade 82. The transfer assist blade 82 is fixedly mounted to a support armature 81 A support baffle 83 is also provided opposite the transfer assist blade 82, forming a channel therethrough for guiding the copy substrate in a direction toward belt 10. A cam 84 is positioned adjacent blade 82 at a location outside of the channel formed between blade 82 and support baffle member 83 for selectively deflecting the blade 82 toward the belt 10. Referring now to FIG. 2, transfer blade 82 is segmented in order to accommodate copy substrates of various widths. The embodiment shown in FIG. 2 demonstrates an arrangement suitable for applying uniform contact pressure to standard copy substrate widths of 114mm, 216mm, and 279mm in a center registered xerographic machine. As will be understood from the embodiment depicted in FIG. 2, a central segment 90 may be driven into the operative position separate from peripheral segments 92 and 94 which may, themselves, be driven to their operative position corresponding with the dimensional width of the copy sheet. Thus, peripheral segments 92 and/or 94 may or may not be paired with their counterpart segments. respectively. on opposite sides of the central segment 90 to provide transfer assist contact along the outside edges of variously dimensioned copy substrates. Central segment 90 or each peripheral segment pair 92 or 94 are moved into the operative position by means of individual cam lobes 85, 86 or 87, which independently contact the surface of the transfer blade 82 to deflect the respective segments toward the belt 10. It will be understood by those of skill in the art that a reasonable extension of this arrangement may include a larger number of segments selectively controlled to apply pressure to many variously dimensioned copy substrates. A further reasonable extension of this arrangement might be configured to provide a central segment along one side with ancillary segments corresponding to the various dimensions of copy sheets along the opposite side, as for example, in a side registered xerographic machine. FIG. 3 depicts a cam shaft of the type which would be appropriate for shifting selected segments of the transfer assist blade of FIG. 2. The cam shaft 84 includes independent lobes 85, 86, 87 corresponding in length to the various dimensions of the particular segments of the transfer assist blade 82. A first lobe 85 corresponds to central segment 90, a second lobe 86 corresponds to the dimensions of the peripheral segments 92 in addition to central segment 90, and a third lobe 87 is provided with a length corresponding to peripheral segments 94 for deflecting those peripheral segments, as well as, peripheral segments 92 and central segment 90. As shown in FIG. 3, the cam is driven by a stepper motor 98 having a rotatable shaft 99 operatively associated with the cam 84 to apply rotational force thereto. In the depicted embodiment, motor 98 enables the cam to be rotated 90 degrees for a typical 114mm wide copy sheet, 180 degrees for an 216mm wide copy sheet and 270 degrees for a typical 279mm wide copy sheet. It will be appreciated that the angular displacement required to be provided by the motor can be reduced by positioning the cam lobes at, for example, 45°, 90° and 135°, or 30°, 60° and 90° or even at lesser intervals. The amount of rotation required for a given copy or print cycle is determined by a sensing mechanism which is typically provided in an electrostatographic machine for detecting the dimension of the output copy sheet. The stepper motor 98 is also coupled to a sensor via a control system (not shown) for detecting the lead edge and trail edge of the copy sheet as it enters into the transfer zone, thereby providing the capability of selectively energizing and de-energizing the stepper motor 98 for deflecting the blade 82 to the operative position against the back of the copy sheet when the copy sheet is present and, conversely, to the non-operative position when the trailing edge of the copy sheet has been detected and the copy sheet is not present. An examplary lead edge/trail edge detection sensor and circuitry therefore is disclosed in US-A-4,341,456 issued to lyer et al. It will be recognized that lead edge detection can be implemented in such a way that the stepper motor 98 can be actuated just prior to the arrival of a copy sheet in the transfer area in order to maximize the utilization of available time for completing the transition between blade movement from the non-operative to the operative positions. The stepper motor control system may include closed or open loop control functions for providing accurate positional measurement and movement of the cam shaft. FIG. 4 illustrates an alternative embodiment of the cam shaft depicted in FIG. 3. In this alternative embodiment, a singular lobe 88 is provided with a continuously increasing height and lengthwise dimension. The lobe configuration of this alternative embodiment permits selective deflection of the segmented transfer blade of FIG. 2 while eliminating undulating motion of various segments of the blade as may be generated by blade contact of the null areas between respective lobes in the cam of FIG. 3. The continuously increasing lengthwise dimension of this alternative embodiment for cam 84 creates continuous deflection of various segments upon actuation as the cam shaft rotates to the appropriate position defined by the size of the output copy sheet Further, the continuously increasing height of the cam lobe in this alternative embodiment permits increased deflection of the blade 82 relative to the angular rotation of the cam 84. Thus. a decrease in stiffness of the blade 82, as might be generated, for example, over the life of the blade, may be compensated for by rotating the cam 84 by an additional amount to cause increased deflection of the blade, thereby delivering nominal pressure to the copy sheet This process also extends the life of the transfer blade so that a blade having borderline flex characteristics might still provide satisfactory results. In addition to the features described above, the alternative embodiment,shown in FIG. 4, also includes a gear arrangement 102, 104 for coupling stepper motor 98 to cam 84, gear 104 being mounted on shaft 99 of motor 98 and gear 102 being mounted on shaft 87 of cam 84. The gear ratio is selected to obtain a desired torque, velocity or other timing advantages as would be understood by one skilled in the art. In operation, when the leading edge of a copy sheet is detected at the inlet to transfer station D, cam 84 is rotated by the energization or activation of motor 98 thereby rotating an independent lobe 85, 86 or 87 or a portion of lobe 88 into contact with the transfer assist blade 82. A sensor, as for example, a light sensing device, detects the leading edge of the copy sheet entering the transfer station and transmits a signal via control circuitry to stepper motor 98. The stepper motor is energized to rotate the cam shaft such that a predetermined cam lobe corresponding the dimensional width of the copy sheet is placed in contact with the transfer assist blade to deflect the transfer assist blade 82 into contact with the back of the copy sheet, thereby pressing the copy sheet against the developed toner powder image on photoconductive belt 10 Thus, the transfer assist blade 82 is deflected into an operative position against the backside of a copy sheet. The contact pressure generated by the transfer assist blade 82 substantially eliminates any spaces or gaps which may exist between the copy sheet and the toner powder image to substantially improve the transfer of the toner powder image to the copy sheet. As the copy sheet passes through the transfer zone, the sensor detects the trailing edge of the copy sheet, transmitting a signal to the stepper motor which causes the cam to rotate in a direction opposite the previous rotation so as to move the cam lobe away from abutting contact with the transfer assist blade 82 to a position in which no cam lobe is in contact with the transfer assist blade. In this position, the transfer assist rests in a non-operative position and does not contact the photoconductive surface of belt 10. Preferably, transfer assist blade 82 is made from a thin flexible sheet material such as Mylar, available from E.I. DuPont de Nemours, Inc. of Wilmington Delaware, or some other polyester sheet material which is elastically deformable. It will be appreciated that the segmented transfer assist blade embodiment disclosed herein is designed to provide contact across the entire width of standard size copy sheets in a center registered xerographic printing machine. Moreover, the combination of this segmented transfer assist blade with the cam 84, permits uniform contact with various sheet dimensions while preventing contact between the peripheral edges of the transfer assist blade and the photoreceptor which may cause damage to the photoreceptor or contamination of the transfer assist blade. In review, the transfer system of the present invention includes a flexible blade member normally resting in a non-stressed position spaced from the photoconductive surface of a belt in a non-operative position A rotatable cam shaft is provided adjacent the blade member for deflecting selected segments of the blade into an operative position for pressing against a copy sheet to create intimate contact between a toner powder image developed on the photoconductive surface and the copy sheet. A corona generating device generates a transfer field effective to transfer the toner powder image from the photoconductive surface to the copy sheet while the contact pressure provided by the transfer assist blade eliminates air gaps between the copy sheet and the photoconductive surface to prevent image deletions.

Claims: An apparatus for providing substantially uniform contact between a copy substrate and a developed image located on an imaging member (10), comprising: contact means (82), adapted to move from a non-operative position spaced from the imaging member (10) to an operative position in contact with the copy substrate on the imaging member (10), for applying pressure against the copy substrate in a direction toward the imaging member (10); and means (84), including, a rotatable cam member comprising a cam lobe (85, 86, 87, 88); for applying a load to said contact means (82) to deflect said contact means (82) into said operative position. The apparatus of claim 1, wherein said contact means includes: a flexible blade member (82); and means (81) for supporting said blade member (82), said supporting means being fixedly mounted. The apparatus of claim 2, wherein said flexible blade member (82) includes a plurality of blade segments (90, 92, 94) such that selected blade segments have a cumulative widthwise dimension corresponding to a widthwise dimension of the copy substrate. The apparatus of claim 3, wherein said rotatable cam member (84) includes a plurality of lobes (85, 86, 87) for applying a load to selected blade segments (90, 92. 94) of said flexible blade member. The apparatus of claim 6, wherein said rotatable cam member (84) is selectively rotated to a predetermined angular position for placing a selected one of said cam lobes (85, 86, 87) into abutting relationship with said flexible blade member (82) for deflecting selected blade segments (90, 92, 94) thereof into said operative position. The apparatus of claim 3, wherein said rotatable cam member (84) includes a singular cam lobe (88) having a continuously varying widthwise dimension for selectively applying a load to selected blade segments (90, 92, 94) of said flexible blade member (82) by selective rotation of the cam member (84) to predetermined angular positions. The apparatus of any one of claims 1 to 6, further including a stepper motor (98) coupled to said cam member (84) for selectively rotating said cam lobe (85, 86, 87; 88) to predetermined angular positions. The apparatus of claim 7, wherein said stepper motor (98) is adapted to rotate said cam member (84) to position said cam lobe (85, 86, 87; 88) in abutting relationship with, or spaced from, said contact means (82) to deflect said contact means (82) into the operative position, or the non-operative position, respectively, in response to detection of a leading or trailing edge of said copy substrate contacting the developed image on the imaging member (10). An electrostatographic printing machine including a transfer station for transferring a developed image from a moving imaging member (10) to a moving copy substrate, including an apparatus for providing substantially uniform intimate contact between the copy substrate and the developed image located on the imaging member (10), in accordance with any one of claims 1 to 8.

Inventors: GROSS ROBERT A, QUESNEL LISBETH S, GROSS, ROBERT A., QUESNEL, LISBETH S.
Applicants: XEROX CORP, XEROX CORPORATION
Application year: 1994
Main classification: G03G15
IPC codes: G03G15